EP0877414A2 - Wafer support devices for use in wafer processing chambers - Google Patents

Wafer support devices for use in wafer processing chambers Download PDF

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Publication number
EP0877414A2
EP0877414A2 EP98303344A EP98303344A EP0877414A2 EP 0877414 A2 EP0877414 A2 EP 0877414A2 EP 98303344 A EP98303344 A EP 98303344A EP 98303344 A EP98303344 A EP 98303344A EP 0877414 A2 EP0877414 A2 EP 0877414A2
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EP
European Patent Office
Prior art keywords
susceptor
wafer
support
wafer support
arms
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP98303344A
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German (de)
French (fr)
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EP0877414A3 (en
Inventor
Bunh Bui
Roger N. Anderson
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Applied Materials Inc
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Applied Materials Inc
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Filing date
Publication date
Application filed by Applied Materials Inc filed Critical Applied Materials Inc
Publication of EP0877414A2 publication Critical patent/EP0877414A2/en
Publication of EP0877414A3 publication Critical patent/EP0877414A3/en
Withdrawn legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/68—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for positioning, orientation or alignment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/683—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping
    • H01L21/687—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches
    • H01L21/68714—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches the wafers being placed on a susceptor, stage or support
    • H01L21/68742—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for supporting or gripping using mechanical means, e.g. chucks, clamps or pinches the wafers being placed on a susceptor, stage or support characterised by a lifting arrangement, e.g. lift pins
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S414/00—Material or article handling
    • Y10S414/135—Associated with semiconductor wafer handling

Definitions

  • the present invention relates to devices utilized in semiconductor production processes. More specifically, the present invention relates to wafer support devices.
  • FIG. 1 illustrates an assembly 100 for supporting a semiconductor wafer 104.
  • Assembly 100 includes a susceptor 102 upon which semiconductor wafer 104 may be placed and supported horizontally.
  • Susceptor 102 is typically supported by susceptor support 108 which includes a shaft 116 with three susceptor arms 109 that outwardly extend therefrom along directions positioned at 120° relative to one another.
  • the susceptor support 108 further includes three legs 110. Each of legs 110 upwardly extends from a corresponding remote end of susceptor arm 109 to engage a bottom surface of susceptor 102 thereby supporting susceptor 102.
  • susceptor support 108 indudes a central leg 117 that upwardly extends from shaft 116 to center susceptor 102.
  • Susceptor 102 includes three through-holes 113 formed therethrough at three locations that are positioned at 120° relative to one another on a circle that has a diameter smaller than a diameter of wafer 104.
  • Three lift pins 112 that support wafer 104 are mounted through the three holes 113 of susceptor 102 of the assembly 100 for supporting wafer 104.
  • Figure 1 shows wafer 104 supported by lift pins 112 in a position where wafer 104 is displaced from susceptor 102 to allow a robot arm 103, placed between wafer 104 and susceptor 102, to insert or remove wafer 104 to/from assembly 100.
  • a displacement between wafer 104 and susceptor 102 may be created by moving the susceptor support 108 downwards relative to wafer 104 while maintaining wafer 104 fixed at the same position.
  • the three holes 113 of susceptor 102 may have an upper portion that is tapered, with a gradual increasing diameter, positioned adjacent to an upper surface of the susceptor 102.
  • a tapered section with gradually increasing diameter is also formed at an upper end of the lift pins 112. This tapered section is conformed to fit in the tapered section of the through-holes 113 so that lift pins 112 may be stopped at the susceptor level when the wafer 104 is placed directly upon the susceptor thereby preventing lift pins 112 from dropping passed the susceptor.
  • Lift pins 112 are typically installed from the top by dropping them through susceptor 102's through-holes 113 and through through-holes 115 of susceptor support arms 109.
  • the installation of lift pins 112 is difficult as susceptor 102 is made of graphite, which is opaque, and which makes it practically impossible to see the through-holes 115 of susceptor arms 109 from above the susceptor, once pins 112 are inserted through through-holes 113.
  • susceptor 102 and wafer 104 are located in a sealed processing chamber (not shown) such as a double domed chamber (not shown), for example, where these devices may be heated by a plurality of heating devices (heat lamps) symmetrically arranged below the susceptor in the chamber, as well as over wafer 104. Heat from the heat lamps radiates through the dome to the underside of the susceptor to heat susceptor 102 as well as wafer 104 that may be positioned thereon. The wafer is also heated by a second set of heat lamps situated above an upper dome positioned over the wafer and the susceptor.
  • a sealed processing chamber such as a double domed chamber (not shown)
  • heat lamps heat lamps
  • Heat lamps radiates through the dome to the underside of the susceptor to heat susceptor 102 as well as wafer 104 that may be positioned thereon.
  • the wafer is also heated by a second set of heat lamps situated above an upper dome positioned over the wafer and the susceptor.
  • a use of central leg 117, that centers susceptor 102, in conjunction with the heating performed by the heat lamps may result in uneven distribution of heat across susceptor 102. This is caused by thermal coupling of the central portion of susceptor 102 to shaft 116 via central leg 117 as well as uneven distribution of heat radiating from the heat lamps to the susceptor 102 due to shadowing of the under side of susceptor 102 by central leg 117. Such uneven heating, or thermal nonuniformity, of susceptor 102 may further result in uneven heating of wafer 104.
  • the wafer support device shown in Figure 1 further may indude a wafer lift device that has three wafer lift arms 120 outwardly extending from wafer central lift 122.
  • the wafer lift arms 120 may typically be integral with the wafer central lift 122.
  • This design is disadvantageous as it requires replacement of the entire wafer lift device (the wafer lift arms 120 and the wafer central lift 122), when a wafer that has a different diameter is processed.
  • Another disadvantage of this design is that movement of susceptor support 108 in a downward direction is limited by wafer lift arms 120 thereby limiting the displacement that may be provided between wafer 104 and susceptor 102.
  • wafer lift arms 120 with pads 123 that support pins 112 create shadowing due to their position.
  • susceptor support 108 with arms 109 may be rotated by a rotation mechanism that may be installed at the lower part of shaft 116.
  • a rotation mechanism that may be installed at the lower part of shaft 116.
  • wafer lift arms 120 and wafer central lift 122 are kept stationary.
  • Such configuration requires that when shaft 116 is rotated a rotation mechanism is installed on the susceptor on the shaft at a position that ensures that when the rotation of the shaft 116 is terminated, the arms 109 guiding pins 112 are stopped at a position where these arms are aligned with wafer lift arms 120 such that a bottom part of pins 112 coincides with pads 123.
  • Such exact installation of the rotation mechanism is limiting and undesirable.
  • a wafer support device with a susceptor support that permits more even heating and thermal uniformity or heat distribution across the susceptor and thereby more even heating or heat distribution across the semiconductor wafer being processed. It is also desirable to provide a wafer support device where the central wafer lift does not need to be changed with every wafer that has a different size. Also, it is desirable to provide a wafer support that does not interfere with the adjustment of the susceptor support.
  • the present invention provides a wafer support device.
  • the wafer support device includes a susceptor having a surface configured to support a wafer.
  • the susceptor has a plurality of guiding recesses.
  • the wafer support device also includes a wafer support that has a plurality of wafer support elements connected thereto.
  • the plurality of wafer support elements is configured to be passed via the plurality of guiding recesses of the susceptor to engage the wafer.
  • the susceptor is configured to be moved relative to the plurality of wafer support elements in a direction substantially orthogonal to the surface of the susceptor.
  • FIG. 2 illustrates a wafer support device 200 according to the present invention.
  • wafer support device 200 is configured to support wafer 205, horizontally from a bottom surface 207 of wafer 205, inside a process chamber (not shown) of a semiconductor production device.
  • Wafer support device 200 indudes susceptor 208 with top surface 210 configured to engage bottom surface 207 of wafer 205.
  • Susceptor 208 is typically disk-shaped.
  • susceptor 208 is made of graphite to provide good thermal conductivity.
  • the present invention is not limited in scope to a disk-shaped susceptor made of graphite, as the susceptor may have other appropriate shapes to support wafer 205 and may be made of materials other than graphite, that provide good thermal conductivity.
  • Susceptor 208 may be provided with a silicon carbide coating to enhance chemical stability thereof to corrosive materials which may be present in a process chamber (not shown) that encloses wafer support device 200 and wafer 205.
  • Susceptor 208 indudes a plurality of guiding recesses 212 positioned on a circle that typically has a diameter smaller than a diameter of wafer 205. However, one skilled in the art may implement the present invention with guiding recesses 212 placed on the susceptor so as to be aligned with a periphery of wafer 205. In one embodiment according to the present invention described herein, guiding recesses 212 are through-holes. Susceptor 208 is supported by a susceptor support that includes a shaft 204 and a first plurality of susceptor support arms (hereinafter referred to as "susceptor support spokes") 216 outwardly extending from shaft 204.
  • susceptor support spokes a first plurality of susceptor support arms
  • the three susceptor support spokes 216 extend from shaft 204 at approximately 120° relative to one another.
  • Spokes 216 may be welded to shaft 204 or mounted thereon in other ways tbat permit axial movement of spokes 216 together with shaft 204 when this shaft is axially moved up or down.
  • spokes 216 extend slightly upwardly towards susceptor 208, but the present invention is not limited in scope to this configuration.
  • the susceptor support indudes, for each susceptor support spoke 216, a susceptor support leg 218 which extends upwardly from a free end of each of susceptor support spokes 216 to engage a bottom surface of susceptor 208 thereby supporting susceptor 208 at three points positioned 120° relative to one another on a cirde having a diameter smaller than a diameter of susceptor 208.
  • the wafer support device according to the present invention is not limited to the three susceptor support legs 218 supporting susceptor 208, but the number of such susceptor support legs may vary according to specific implementations. Also, instead of having a discrete number of susceptor support legs, one may design the wafer support device according to the present invention to utilize a continuous (360°) susceptor support "leg" such as a cylindrical collar.
  • the susceptor support may be moved upwardly and downwardly as shaft 204 may be coupled at a lower part thereof to a motor that may cause upward and downward movement of the shaft and therefore of the susceptor support.
  • the upward or downward movement of the susceptor support may cause a displacement of susceptor 208, relative to wafer 205, that is supported by way of a wafer support 222 (hereinafter referred to as a "pin lift device 222°).
  • Pin lift device 222 is typically made of quartz, but one skilled in the art may use other material with properties closely related to quartz.
  • Pin lift device 222 includes a central portion, hub 223, mounted onto susceptor support spokes 216 adjacent an upper part of shaft 204 from where susceptor support arms 216 outwardly extend.
  • Pin lift device 222 further indudes a plurality of pin lift arms 226 (hereinafter referred to as “pin lift spokes 226") that are connected to an upper part of hub 223. Moreover, pin lift device 222 indudes a plurality of wafer support elements 224 (hereinafter referred to as “lift pins”) that are attached to a free end (remote, from the hub 223) of spokes 226. In one embodiment according to the present invention described herein pin lift device 222 includes three pin lift spokes 226 and three lift pins 224 corresponding to pin lift spokes 226. However, the present invention is not limited in scope in this respect to three spokes 226 and three lift pins 224.
  • Pin lift spokes 226 are positioned 120° relative to one another and extend outwardly and slightly upwardly towards a periphery 220 of the wafer. Spokes 226 are attached to hub 223 such that hub 223 and spokes 226 may move together axially upwardly or downwardly, or rotationally. Spokes 226 may be integral with hub 223, but the present invention is not limited in scope in this respect. Also, lift pins 224 may be integral with spokes 226, to move upward or downward together with hub 223 when hub 223 is axially moved up or down or when hub 223 is rotated.
  • lift pins 224 extend vertically on above and below spokes 226, each pin 224 having a lower part 230 extending beneath spoke 226 and an upper part 232 extending, above spoke 226, towards guiding recesses 212.
  • Pin lift device 222 is configured such that lift pins 224 are aligned with the guiding recesses 212 of susceptor 208 to permit a portion of the upper part 232 of lift pins 224 to pass through guiding recesses 212 when susceptor 208 is moved upwardly or downwardly relative to pin lift device 222.
  • Pin lift device 222 supports lift pins 224 such that guiding recesses 212 of susceptor 208 do not need to have a tapered upper portion but these recesses may just indude a clearance hole reducing the cost of fabricating susceptor 208.
  • the lower part 230 of each lift pin 224 is configured to pass through a corresponding through-hole 250 made through the plurality of spokes 216.
  • pins 224 may move upwardly and downwardly relative to susceptor support arms 216 and to susceptor 208.
  • the up and down movement, relative to susceptor 208, of the pin lift device 222 and therefore of pins 224 may be caused by a vertical movement of the susceptor support while pin lift device 222 is maintained stationary.
  • susceptor support arms 216 with hub 223, spokes 226, and pins 224 may rotate together when such rotation is induced by a rotating device (not shown) that may be mounted at a lower part of shaft 204 to impart a rotational movement to susceptor support.
  • the wafer support device according to the present invention with pin lift device 222 has arms 226 substantially (superimposed) aligned with arms 216 of the susceptor support. These arms are moved together, in alignment with arms 216 when a rotation device is installed and rotates the shaft 204. By having arms 226 positioned above and in alignment with arms 216, the shadowing problem explained in connection with the embodiment described in Figure 1 is substantially reduced. Additionally, by having arms 26 configured to rotate together and in alignment with arms 216, the rotation device may be installed at any position onto the shaft 204 and does not have to be limited in installation to only three positions as the assembly described in connection with Figure 1. For information related to a rotating device or a rotating mechanism that may possibly be used in connection with the present invention, please see United States patent 5,421,893, assigned to Applied Materials, Inc.
  • FIG 3 illustrates, in a simplified manner, a pin lift device 222 including central hub 223, spokes 226 outwardly extending therefrom, and lift pins 224 vertically extending from spokes 226.
  • Central hub 223 has a generally cylindrical hollow shape and includes slits 238 longitudinally extending along hub 223. Slits 238 extend from a base 240 of hub 223 to upper ridges 242. Slits 238 are configured to pass therethrough susceptor support spokes 216 (shown in Figure 2). Upper ridges 242 are configured to prevent susceptor support spokes 216 from moving further up relative to hub 223 once susceptor support spokes 216 come into engagement with upper ridges 242.
  • spokes 226 are superimposed with slits 238 such that upon mounting of susceptor support spokes 216 through slits 238 spokes 226 and 216 are aligned. Such alignment causes a reduction in the shadowing otherwise caused have spokes 226 not been aligned with spokes 216.
  • one way of causing a displacement between wafer 205 and susceptor 208 is by producing a relative movement of susceptor support spokes 216 through slits 238 of hub 223 ( Figure 3) while pin lift device 222 is maintained fixed.
  • This relative movement may occur when base 240 of hub 223 ( Figure 3) comes into engagement with a rim 253 of a wafer central lift device 252.
  • the wafer central lift device 252 has a generally cylindrical shape with a hollow interior configured to accommodate shaft 204.
  • the wafer central lift device 252 may be mounted at a lower part thereof 254 to a motor (not shown) that may cause an "up” or “down” movement of wafer central lift device 252.
  • any upward movement of the susceptor support spokes 216 causes pin lift device 222 and thus wafer 205 to move along with susceptor 208 such that the distance between the wafer 205 and the susceptor 208 remains unchanged.
  • Figure 4 illustrates a second embodiment of a wafer support device 402 according to the present invention.
  • pin lift device 422 indudes lift pins 424 that upwardly extend from spokes 426 of the pin lift device 422 from one side (the upper side) of these spokes 426.
  • the pin lift device 422 is thus less fragile and its mounting onto the wafer support device 402 is greatly facilitated by only having to pass pins 424 through holes 412.
  • the susceptor support may indude a center post 440 positioned at an upper end thereof.
  • Center post 440 is built as a step, with a diameter thereof smaller than a diameter of shaft 404, to provide additional guidance to the pin lift device 442.
  • the pin lift device 422 shown in Figure 4 indudes an annular element 450 that has a hollow interior with a diameter substantially equal to the diameter of post 440.
  • center post 440 provides susceptor support additional weight that helps the susceptor support to move down, by virtue of gravity, towards upper rim 453 of wafer lift device 452.
  • Figure 5 illustrates a third embodiment of a wafer support device 502 according to the present invention.
  • pin lift device 522 is designed so that lift pins 524, that extend upwardly from a free end of spokes 526, engage wafer 505 at a periphery 520 thereof. By lifting wafer 505 from the periphery thereof, this embodiment helps reduce the cool/hot spots on the body of the wafer that otherwise may be produced by pins 224 of Figure 1.
  • wafer support 502 may have shaft 504 provided at an upper part thereof with stepped posts 550 and 552.
  • Post 550 has a diameter smaller than a diameter of shaft 504.
  • post 552 has a diameter smaller than the diameter of post 550.
  • Post 522 is provided for centering susceptor 508. Note that the relatively small diameter of post 552 minimizes the shadow created at the center of susceptor support 508.
  • Figure 6 illustrates a flow chart for process of providing support to a wafer in an apparatus for processing semiconductor wafers.
  • the process starts at 602 from where it passes to block 604.
  • a wafer support is mounted onto a susceptor support.
  • the wafer support has a plurality wafer support elements extending therefrom.
  • the wafer support may be a wafer support as the wafer support illustrated in connection with Figures 2-5.
  • the wafer support elements that extend from the wafer support may be the lift pins shown in Figures 2-5.
  • the process then passes to block 606 where a susceptor is mounted onto the susceptor support.
  • the susceptor has a plurality of guiding recesses that are configured to be elements when the susceptor is mounted onto the susceptor support.
  • the susceptor may be mounted onto the susceptor support such that the susceptor support holds the susceptor at a number of discrete points as shown in the embodiments described in connection with Figures 2-5.
  • the process then passes to block 608 where a wafer is placed onto the susceptor if the wafer support elements (pins) do not protrude through the guiding recesses onto the susceptor.
  • the wafer may alternatively be mounted onto the wafer support elements such that the wafer is aligned with the wafer support.

Abstract

The disclosure relates to a wafer support device (200). The wafer support device includes a susceptor (208) having a surface (210) configured to support a bottom surface (207) of a wafer (205). The susceptor has a plurality of guiding recesses (212). The wafer support device also includes a pin lift (222) that has a plurality of pins (224) extending therefrom. The plurality of pins is configured to be passed via the plurality of guiding recesses of the susceptor to engage the bottom surface of the wafer. The susceptor is configured to be moved relative to the plurality of pins in a direction substantially orthogonal to the surface of the susceptor.

Description

The present invention relates to devices utilized in semiconductor production processes. More specifically, the present invention relates to wafer support devices.
In the course of forming integrated circuit structures on semiconductor wafers, certain processes are utilized that involve the use of heated susceptors or wafer supports located in enclosed chambers where these processes take place. Some of these processes include, for example, growth of an epitaxial silicon layer, the formation of a thermal oxide or thermal nitride layer over silicon, the rapid thermal annealing of integrated circuit structures already formed on the wafer, etc. Typically, devices such as susceptors, susceptor supports, and wafer supports may be used for supporting the wafers horizontally from below.
Figure 1 illustrates an assembly 100 for supporting a semiconductor wafer 104. Assembly 100 includes a susceptor 102 upon which semiconductor wafer 104 may be placed and supported horizontally. Susceptor 102 is typically supported by susceptor support 108 which includes a shaft 116 with three susceptor arms 109 that outwardly extend therefrom along directions positioned at 120° relative to one another. The susceptor support 108 further includes three legs 110. Each of legs 110 upwardly extends from a corresponding remote end of susceptor arm 109 to engage a bottom surface of susceptor 102 thereby supporting susceptor 102. Moreover, susceptor support 108 indudes a central leg 117 that upwardly extends from shaft 116 to center susceptor 102.
Susceptor 102 includes three through-holes 113 formed therethrough at three locations that are positioned at 120° relative to one another on a circle that has a diameter smaller than a diameter of wafer 104. Three lift pins 112 that support wafer 104 are mounted through the three holes 113 of susceptor 102 of the assembly 100 for supporting wafer 104. Figure 1 shows wafer 104 supported by lift pins 112 in a position where wafer 104 is displaced from susceptor 102 to allow a robot arm 103, placed between wafer 104 and susceptor 102, to insert or remove wafer 104 to/from assembly 100. A displacement between wafer 104 and susceptor 102 may be created by moving the susceptor support 108 downwards relative to wafer 104 while maintaining wafer 104 fixed at the same position.
The three holes 113 of susceptor 102 may have an upper portion that is tapered, with a gradual increasing diameter, positioned adjacent to an upper surface of the susceptor 102. A tapered section with gradually increasing diameter is also formed at an upper end of the lift pins 112. This tapered section is conformed to fit in the tapered section of the through-holes 113 so that lift pins 112 may be stopped at the susceptor level when the wafer 104 is placed directly upon the susceptor thereby preventing lift pins 112 from dropping passed the susceptor.
Lift pins 112 are typically installed from the top by dropping them through susceptor 102's through-holes 113 and through through-holes 115 of susceptor support arms 109. The installation of lift pins 112 is difficult as susceptor 102 is made of graphite, which is opaque, and which makes it practically impossible to see the through-holes 115 of susceptor arms 109 from above the susceptor, once pins 112 are inserted through through-holes 113.
Typically, susceptor 102 and wafer 104, that may be mounted thereon, are located in a sealed processing chamber (not shown) such as a double domed chamber (not shown), for example, where these devices may be heated by a plurality of heating devices (heat lamps) symmetrically arranged below the susceptor in the chamber, as well as over wafer 104. Heat from the heat lamps radiates through the dome to the underside of the susceptor to heat susceptor 102 as well as wafer 104 that may be positioned thereon. The wafer is also heated by a second set of heat lamps situated above an upper dome positioned over the wafer and the susceptor.
A use of central leg 117, that centers susceptor 102, in conjunction with the heating performed by the heat lamps may result in uneven distribution of heat across susceptor 102. This is caused by thermal coupling of the central portion of susceptor 102 to shaft 116 via central leg 117 as well as uneven distribution of heat radiating from the heat lamps to the susceptor 102 due to shadowing of the under side of susceptor 102 by central leg 117. Such uneven heating, or thermal nonuniformity, of susceptor 102 may further result in uneven heating of wafer 104.
The wafer support device shown in Figure 1 further may indude a wafer lift device that has three wafer lift arms 120 outwardly extending from wafer central lift 122. The wafer lift arms 120 may typically be integral with the wafer central lift 122. This design is disadvantageous as it requires replacement of the entire wafer lift device (the wafer lift arms 120 and the wafer central lift 122), when a wafer that has a different diameter is processed. Another disadvantage of this design, is that movement of susceptor support 108 in a downward direction is limited by wafer lift arms 120 thereby limiting the displacement that may be provided between wafer 104 and susceptor 102. Yet another disadvantage is that wafer lift arms 120 with pads 123 that support pins 112 create shadowing due to their position.
Furthermore, susceptor support 108 with arms 109 may be rotated by a rotation mechanism that may be installed at the lower part of shaft 116. When such rotation occurs wafer lift arms 120 and wafer central lift 122 are kept stationary. Such configuration requires that when shaft 116 is rotated a rotation mechanism is installed on the susceptor on the shaft at a position that ensures that when the rotation of the shaft 116 is terminated, the arms 109 guiding pins 112 are stopped at a position where these arms are aligned with wafer lift arms 120 such that a bottom part of pins 112 coincides with pads 123. Such exact installation of the rotation mechanism is limiting and undesirable.
It is desirable to provide a wafer support device with a susceptor support that permits more even heating and thermal uniformity or heat distribution across the susceptor and thereby more even heating or heat distribution across the semiconductor wafer being processed. It is also desirable to provide a wafer support device where the central wafer lift does not need to be changed with every wafer that has a different size. Also, it is desirable to provide a wafer support that does not interfere with the adjustment of the susceptor support.
The present invention provides a wafer support device. The wafer support device includes a susceptor having a surface configured to support a wafer. The susceptor has a plurality of guiding recesses. The wafer support device also includes a wafer support that has a plurality of wafer support elements connected thereto. The plurality of wafer support elements is configured to be passed via the plurality of guiding recesses of the susceptor to engage the wafer. The susceptor is configured to be moved relative to the plurality of wafer support elements in a direction substantially orthogonal to the surface of the susceptor.
The features, aspects, and advantages of the present invention will become more fully apparent from the following Detailed Description, appended claims, and accompanying drawings in which :
  • Figure 1 illustrates an assembly for supporting a semiconductor wafer;
  • Figure 2 illustrates a wafer support device according to the present invention;
  • Figure 3 illustrates a wafer support utilized in connection with the wafer support device according to the present invention;
  • Figure 4 illustrates a second embodiment of a wafer support device according to the present invention;
  • Figure 5 illustrates a third embodiment of the wafer support device according to the present invention; and
  • Figure 6 illustrates a method according to the present invention for providing support to a wafer.
    • In the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, one of ordinary skill in the art will recognize that the invention may be practiced without these specific details. In some instances, well-known structures, and techniques have not been shown in detail to avoid obscuring the present invention.
    Figure 2 illustrates a wafer support device 200 according to the present invention. Typically, wafer support device 200 is configured to support wafer 205, horizontally from a bottom surface 207 of wafer 205, inside a process chamber (not shown) of a semiconductor production device. Wafer support device 200 indudes susceptor 208 with top surface 210 configured to engage bottom surface 207 of wafer 205. Susceptor 208 is typically disk-shaped. Also susceptor 208 is made of graphite to provide good thermal conductivity. However, the present invention is not limited in scope to a disk-shaped susceptor made of graphite, as the susceptor may have other appropriate shapes to support wafer 205 and may be made of materials other than graphite, that provide good thermal conductivity. Susceptor 208 may be provided with a silicon carbide coating to enhance chemical stability thereof to corrosive materials which may be present in a process chamber (not shown) that encloses wafer support device 200 and wafer 205.
    Susceptor 208 indudes a plurality of guiding recesses 212 positioned on a circle that typically has a diameter smaller than a diameter of wafer 205. However, one skilled in the art may implement the present invention with guiding recesses 212 placed on the susceptor so as to be aligned with a periphery of wafer 205. In one embodiment according to the present invention described herein, guiding recesses 212 are through-holes. Susceptor 208 is supported by a susceptor support that includes a shaft 204 and a first plurality of susceptor support arms (hereinafter referred to as "susceptor support spokes") 216 outwardly extending from shaft 204. In one embodiment according to the present invention the three susceptor support spokes 216 extend from shaft 204 at approximately 120° relative to one another. Spokes 216 may be welded to shaft 204 or mounted thereon in other ways tbat permit axial movement of spokes 216 together with shaft 204 when this shaft is axially moved up or down. In the embodiment of the present invention described in connection with Figure 2, spokes 216 extend slightly upwardly towards susceptor 208, but the present invention is not limited in scope to this configuration. Furthermore, the susceptor support indudes, for each susceptor support spoke 216, a susceptor support leg 218 which extends upwardly from a free end of each of susceptor support spokes 216 to engage a bottom surface of susceptor 208 thereby supporting susceptor 208 at three points positioned 120° relative to one another on a cirde having a diameter smaller than a diameter of susceptor 208.
    It should be appreciated by one skilled in the art that the wafer support device according to the present invention is not limited to the three susceptor support legs 218 supporting susceptor 208, but the number of such susceptor support legs may vary according to specific implementations. Also, instead of having a discrete number of susceptor support legs, one may design the wafer support device according to the present invention to utilize a continuous (360°) susceptor support "leg" such as a cylindrical collar.
    Typically the susceptor support may be moved upwardly and downwardly as shaft 204 may be coupled at a lower part thereof to a motor that may cause upward and downward movement of the shaft and therefore of the susceptor support. The upward or downward movement of the susceptor support may cause a displacement of susceptor 208, relative to wafer 205, that is supported by way of a wafer support 222 (hereinafter referred to as a "pin lift device 222°). Pin lift device 222 is typically made of quartz, but one skilled in the art may use other material with properties closely related to quartz. Pin lift device 222 includes a central portion, hub 223, mounted onto susceptor support spokes 216 adjacent an upper part of shaft 204 from where susceptor support arms 216 outwardly extend. Pin lift device 222 further indudes a plurality of pin lift arms 226 (hereinafter referred to as "pin lift spokes 226") that are connected to an upper part of hub 223. Moreover, pin lift device 222 indudes a plurality of wafer support elements 224 (hereinafter referred to as "lift pins") that are attached to a free end (remote, from the hub 223) of spokes 226. In one embodiment according to the present invention described herein pin lift device 222 includes three pin lift spokes 226 and three lift pins 224 corresponding to pin lift spokes 226. However, the present invention is not limited in scope in this respect to three spokes 226 and three lift pins 224.
    Pin lift spokes 226 are positioned 120° relative to one another and extend outwardly and slightly upwardly towards a periphery 220 of the wafer. Spokes 226 are attached to hub 223 such that hub 223 and spokes 226 may move together axially upwardly or downwardly, or rotationally. Spokes 226 may be integral with hub 223, but the present invention is not limited in scope in this respect. Also, lift pins 224 may be integral with spokes 226, to move upward or downward together with hub 223 when hub 223 is axially moved up or down or when hub 223 is rotated. In one embodiment according to the present invention described herein, lift pins 224 extend vertically on above and below spokes 226, each pin 224 having a lower part 230 extending beneath spoke 226 and an upper part 232 extending, above spoke 226, towards guiding recesses 212.
    Pin lift device 222 is configured such that lift pins 224 are aligned with the guiding recesses 212 of susceptor 208 to permit a portion of the upper part 232 of lift pins 224 to pass through guiding recesses 212 when susceptor 208 is moved upwardly or downwardly relative to pin lift device 222. Pin lift device 222 supports lift pins 224 such that guiding recesses 212 of susceptor 208 do not need to have a tapered upper portion but these recesses may just indude a clearance hole reducing the cost of fabricating susceptor 208. The lower part 230 of each lift pin 224 is configured to pass through a corresponding through-hole 250 made through the plurality of spokes 216. Accordingly, pins 224 may move upwardly and downwardly relative to susceptor support arms 216 and to susceptor 208. The up and down movement, relative to susceptor 208, of the pin lift device 222 and therefore of pins 224 may be caused by a vertical movement of the susceptor support while pin lift device 222 is maintained stationary. Note that susceptor support arms 216 with hub 223, spokes 226, and pins 224 may rotate together when such rotation is induced by a rotating device (not shown) that may be mounted at a lower part of shaft 204 to impart a rotational movement to susceptor support.
    The wafer support device according to the present invention with pin lift device 222 has arms 226 substantially (superimposed) aligned with arms 216 of the susceptor support. These arms are moved together, in alignment with arms 216 when a rotation device is installed and rotates the shaft 204. By having arms 226 positioned above and in alignment with arms 216, the shadowing problem explained in connection with the embodiment described in Figure 1 is substantially reduced. Additionally, by having arms 26 configured to rotate together and in alignment with arms 216, the rotation device may be installed at any position onto the shaft 204 and does not have to be limited in installation to only three positions as the assembly described in connection with Figure 1. For information related to a rotating device or a rotating mechanism that may possibly be used in connection with the present invention, please see United States patent 5,421,893, assigned to Applied Materials, Inc.
    Figure 3 illustrates, in a simplified manner, a pin lift device 222 including central hub 223, spokes 226 outwardly extending therefrom, and lift pins 224 vertically extending from spokes 226. Central hub 223 has a generally cylindrical hollow shape and includes slits 238 longitudinally extending along hub 223. Slits 238 extend from a base 240 of hub 223 to upper ridges 242. Slits 238 are configured to pass therethrough susceptor support spokes 216 (shown in Figure 2). Upper ridges 242 are configured to prevent susceptor support spokes 216 from moving further up relative to hub 223 once susceptor support spokes 216 come into engagement with upper ridges 242. Note that spokes 226 are superimposed with slits 238 such that upon mounting of susceptor support spokes 216 through slits 238 spokes 226 and 216 are aligned. Such alignment causes a reduction in the shadowing otherwise caused have spokes 226 not been aligned with spokes 216.
    Going back to Figure 2, one way of causing a displacement between wafer 205 and susceptor 208 is by producing a relative movement of susceptor support spokes 216 through slits 238 of hub 223 (Figure 3) while pin lift device 222 is maintained fixed. This relative movement may occur when base 240 of hub 223 (Figure 3) comes into engagement with a rim 253 of a wafer central lift device 252. The wafer central lift device 252 has a generally cylindrical shape with a hollow interior configured to accommodate shaft 204. The wafer central lift device 252 may be mounted at a lower part thereof 254 to a motor (not shown) that may cause an "up" or "down" movement of wafer central lift device 252. Once the base 240 of hub 223 (Fig. 3) engages upper rim 253 of wafer lift device 252 and the wafer central lift device 252 is maintained stationary, shaft 204 may move downwards "pulling" along downwardly susceptor support spokes 216 via slits 238 of hub 223 (Fig. 3) and causing susceptor 208 to move downwardly. By keeping the wafer central lift device 252 stationary and, accordingly, pin lift device 222 stationary, the downward movement of the susceptor support causes a displacement between wafer 205, that remains stationary, as being supported by pins 224, and susceptor 208 that is moved downwardly by virtue of the movement of the susceptor support. The configuration of the present invention with pin lift device 222 permits increased displacement of the susceptor support relative to the displacement of the susceptor support permitted by conventional wafer support devices.
    When the susceptor support is moved upwardly, the displacement between the wafer 205 and susceptor 208 decreases. When susceptor support spokes 216 reach upper ridge 242 of hub 223, any upward movement of the susceptor support spokes 216 causes pin lift device 222 and thus wafer 205 to move along with susceptor 208 such that the distance between the wafer 205 and the susceptor 208 remains unchanged.
    Figure 4 illustrates a second embodiment of a wafer support device 402 according to the present invention. In this embodiment, pin lift device 422 indudes lift pins 424 that upwardly extend from spokes 426 of the pin lift device 422 from one side (the upper side) of these spokes 426. According to this embodiment, there is no need to use guiding recesses through susceptor support spokes 416 to permit upward and downward movement of pins 424 but rather holes 412, provided in susceptor 408, suffice to guide lift pins 424 upwardly and downwardly. The pin lift device 422 is thus less fragile and its mounting onto the wafer support device 402 is greatly facilitated by only having to pass pins 424 through holes 412.
    Optionally, the susceptor support may indude a center post 440 positioned at an upper end thereof. Center post 440 is built as a step, with a diameter thereof smaller than a diameter of shaft 404, to provide additional guidance to the pin lift device 442. The pin lift device 422 shown in Figure 4 indudes an annular element 450 that has a hollow interior with a diameter substantially equal to the diameter of post 440. Also center post 440 provides susceptor support additional weight that helps the susceptor support to move down, by virtue of gravity, towards upper rim 453 of wafer lift device 452.
    Figure 5 illustrates a third embodiment of a wafer support device 502 according to the present invention. In this embodiment pin lift device 522 is designed so that lift pins 524, that extend upwardly from a free end of spokes 526, engage wafer 505 at a periphery 520 thereof. By lifting wafer 505 from the periphery thereof, this embodiment helps reduce the cool/hot spots on the body of the wafer that otherwise may be produced by pins 224 of Figure 1. Additionally, as an option, wafer support 502 may have shaft 504 provided at an upper part thereof with stepped posts 550 and 552. Post 550 has a diameter smaller than a diameter of shaft 504. Moreover, post 552 has a diameter smaller than the diameter of post 550. Post 522 is provided for centering susceptor 508. Note that the relatively small diameter of post 552 minimizes the shadow created at the center of susceptor support 508.
    Figure 6 illustrates a flow chart for process of providing support to a wafer in an apparatus for processing semiconductor wafers. The process starts at 602 from where it passes to block 604. At block 604 a wafer support is mounted onto a susceptor support. The wafer support has a plurality wafer support elements extending therefrom. The wafer support may be a wafer support as the wafer support illustrated in connection with Figures 2-5. The wafer support elements that extend from the wafer support may be the lift pins shown in Figures 2-5. The process then passes to block 606 where a susceptor is mounted onto the susceptor support. The susceptor has a plurality of guiding recesses that are configured to be elements when the susceptor is mounted onto the susceptor support. The susceptor may be mounted onto the susceptor support such that the susceptor support holds the susceptor at a number of discrete points as shown in the embodiments described in connection with Figures 2-5. The process then passes to block 608 where a wafer is placed onto the susceptor if the wafer support elements (pins) do not protrude through the guiding recesses onto the susceptor. The wafer may alternatively be mounted onto the wafer support elements such that the wafer is aligned with the wafer support.
    In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will however be evident that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. Therefore, the scope of the invention should be limited only by the appended claims.

    Claims (37)

    1. A wafer support device comprising:
      a susceptor having a surface configured to support a wafer, said susceptor having a plurality of guiding recesses,
      a wafer support having a central portion and a plurality of wafer support elements connected thereto, said plurality of wafer support elements configured to be passed via said plurality of guiding recesses of said susceptor to engage said wafer, and
         wherein said susceptor is configured to be moved in a direction substantially orthogonal to said surface thereof.
    2. A wafer support device as claimed in claim 1, wherein said wafer support includes a first plurality of arms outwardly extending from said central portion, said first plurality of arms each having a free end.
    3. A wafer support device as claimed in claim 2, wherein each of said plurality of wafer support elements, of said wafer support, extends from a corresponding arm of said first plurality of arms towards a corresponding guiding recess of said susceptor.
    4. A wafer support as claimed in claim 3, wherein said plurality of wafer support elements are aligned with said plurality of guiding recesses of said susceptor.
    5. A wafer support device as claimed in any of claims 1 to 4, further including a wafer lift device configured to engage said wafer support and to move said wafer support in a direction substantially orthogonal relative to said surface of said susceptor.
    6. A wafer support device as claimed in any of claims 1 to 4 further including a susceptor support configured to support said susceptor and to be moved in a direction substantially orthogonal to said surface of said susceptor.
    7. A wafer support as claimed in claim 6, wherein said susceptor support includes a shaft, and a second plurality of arms extending from said shaft.
    8. A wafer support as claimed in claim 7 when appendant to any of claims 2 to 4, wherein said wafer support is configured with said first plurality of arms to be aligned with said second plurality of arms.
    9. A wafer support as claimed in claim 7 or claim 8, wherein said second plurality of arms includes a plurality of through-holes configured to be aligned with said guiding recesses of said susceptor when said susceptor is supported by said susceptor support.
    10. A wafer support device as claimed in any of claims 7 to 9, wherein said central portion includes a hub having a plurality of slits for permitting said second plurality of arms to be guided therethrough.
    11. A wafer support devices as claimed in claim 10, wherein said hub includes a plurality of ridges terminating said slits, said plurality of ridges configured to stop said second plurality of arms from moving upwardly relative to said hub, when said second plurality of arms engage said plurality of ridges.
    12. A wafer support as claimed in claim 10 or claim 11, wherein said plurality of slits are aligned with said first plurality of arms.
    13. A wafer support device as claimed in any of claims 1 to 12, wherein said wafer support elements are configured to engage said wafer at a periphery thereof.
    14. A wafer support device as claimed in any of claims 6 to 13, further including a device for imparting rotary movement to said susceptor support.
    15. A wafer support device as claimed in claim 14, wherein said wafer support configured to be rotated with said susceptor support when rotary movement is imparted to said susceptor support.
    16. A support device as claimed in any of claims 1 to 15, wherein said plurality of wafer support elements include a plurality of wafer support pins.
    17. A wafer support device as claimed in any of claims 1 to 16, wherein said wafer support elements are configured to be moved together with said wafer support when said wafer support is moved.
    18. An apparatus comprising:
      a chamber including,
      a susceptor having a surface configured to support a wafer, said susceptor having a plurality of guiding recesses,
      a wafer support having a central portion and a plurality of wafer support elements connected thereto, said plurality of wafer support elements configured to be passed via said plurality of guiding recesses of said susceptor to engage said wafer; and
         wherein said susceptor configured to be moved in a direction substantially orthogonal to said surface thereof.
    19. An apparatus as claimed in claim 18, wherein said wafer support includes a first plurality of arms outwardly extending from said central portion, said first plurality of arms each having a free end.
    20. An apparatus as claimed in claim 19, wherein each of said plurality of wafer support elements, of said wafer support, extends from a corresponding arm of said first plurality of arms towards a corresponding guiding recess of said susceptor.
    21. A wafer support as claimed in any of claims 18 to 20, wherein said plurality of wafer support elements are aligned with said plurality of guiding recesses of said susceptor.
    22. An apparatus as claimed in any of claims 18 to 21, further including a wafer lift device configured to engage said wafer support and to move said wafer support in a direction substantially orthogonal relative to said surface of said susceptor.
    23. An apparatus as claimed in any of claims 18 to 22, further including a susceptor support configured to support said susceptor and to be moved in a direction substantially orthogonal to said surface of said susceptor.
    24. An apparatus as claimed in claim 23, wherein said susceptor support includes a shaft, and a second plurality of arms extending from said shaft.
    25. An apparatus as claimed in claim 24, wherein said second plurality of arms includes a plurality of through-holes configured to be aligned with said guiding recesses of said susceptor when said susceptor is supported by said susceptor support.
    26. An apparatus as claimed in claim 24 or claim 25, wherein said central portion includes a hub having a plurality of slits for permitting said second plurality of arms to be guided therethrough.
    27. An apparatus as claimed in claim 26, wherein said hub includes a plurality of ridges terminating said slits, said plurality of ridges configured to stop said second plurality of arms from moving relative to said hub, when said second plurality of arms engage said plurality of ridges.
    28. An apparatus as claimed in any of claims 23 to 27 further including a device for imparting rotary movement to said susceptor support.
    29. An apparatus as claimed in any of claims 18 to 27, wherein said wafer support elements configured to engage said wafer at a periphery thereof.
    30. An apparatus as claimed in claim 29, wherein said wafer support configured to be rotated with said susceptor support when rotary movement is imparted to said susceptor support.
    31. An apparatus as claimed in any of claims 18 to 30, wherein said plurality of wafer support elements include a plurality of wafer support pins.
    32. An apparatus as claimed in any of claims 18 to 31, wherein said wafer support elements are configured to be moved together with said wafer support when said wafer support is moved.
    33. In an apparatus for processing semiconductor wafers, a method for support a wafer, the method of comprising the steps of:
      a) mounting a wafer support onto a susceptor support, the wafer support having a plurality of wafer support elements extending therefrom;
      b) mounting a susceptor onto said susceptor support, said susceptor having a plurality of guiding recesses configured to be aligned with said wafer support elements when said susceptor is mounted onto said susceptor support; and
      c) placing a wafer onto one of said susceptor and said wafer support elements.
    34. A method as claimed in claim 33, further comprising the step of supporting said wafer by way of said wafer support elements when said susceptor support is moved downwardly relative to said wafer support elements.
    35. A method as claimed in claim 33 or claim 34, further including rotating said wafer support together with said susceptor support.
    36. A wafer support device comprising:
      a susceptor having a surface configured to support a wafer; said susceptor having a plurality of guiding recesses;
      a susceptor support configured to support said susceptor;
      a wafer support, placed between said susceptor and said susceptor support, said wafer support having a central position and a plurality of wafer support elements connected thereto, said plurality of wafer support elements configured to be passed via said plurality of guiding recesses of said susceptor to engage said wafer; and
      wherein said susceptor support configured to be moved beneath said wafer support in a direction substantially orthogonal to said surface thereof.
    37. A wafer support device comprising:
      a susceptor having a surface configured to support a wafer, said susceptor having a plurality of guiding recesses;
      a susceptor support configured to support said susceptor;
      a wafer support, placed between said susceptor and said susceptor support, said wafer support having a central portion and a plurality of wafer support elements connected thereto, said plurality of wafer support elements configured to be passed via said plurality of guiding recesses of said susceptor to engage said wafer; and
      a wafer lift configured to engage said wafer support and to move said wafer support in a direction substantially orthogonal to said surface of said susceptor.
    EP98303344A 1997-04-30 1998-04-29 Wafer support devices for use in wafer processing chambers Withdrawn EP0877414A3 (en)

    Applications Claiming Priority (2)

    Application Number Priority Date Filing Date Title
    US846250 1997-04-30
    US08/846,250 US6190113B1 (en) 1997-04-30 1997-04-30 Quartz pin lift for single wafer chemical vapor deposition/etch process chamber

    Publications (2)

    Publication Number Publication Date
    EP0877414A2 true EP0877414A2 (en) 1998-11-11
    EP0877414A3 EP0877414A3 (en) 2004-05-12

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    EP (1) EP0877414A3 (en)
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    KR100574241B1 (en) 2006-07-25
    EP0877414A3 (en) 2004-05-12
    US6190113B1 (en) 2001-02-20
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    KR19980081849A (en) 1998-11-25
    JPH10335435A (en) 1998-12-18

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